Ditch Witch JT4020 User manual

ID0201755
JT4020
All Terrain Rack & Pinion
ISSUE NO. 04PL06/11
For Replacement Copy Order P/N 053-1216
This manual contains information concerning the following models:
JT4020 All Terrain Rack & Pinion Directional Drilling System
This product is covered by one or more of the following patents:
US B1 4,858,704; 4,953,638; 5,148,880; 5,242,026; 5,341,887; 5,490,569; 5,684,466;
5,713,423, 5,794,719; 5,880,680; 5,941,322; 6,085,852; 6,109,371; 6,179,065; 6,216,803;
6,250,403; 6,250,404; 6,290,606; 6,311,790; 6,411,094; 6,543,551; 6,550,547; 6,672,409;
6,739,413; 6,776,246; 6,808,210; 6,827,158; RE37,450; RE37,923; RE37,975; RE38,418
AU 689,533; 706,544; 718,034, 755,862
CA 2,156,398
FR 674,093
DE 694 17 019; 695 29 634; 297 01 406
EP 0683845; 0674093; 0817901; 0846841
GB 2,209,239; 2,312,006; EP674,093; EP846,841
JP 3,458,247
Other U.S. and foreign patents pending
Copyright 2008, 2011 by The Charles Machine Works, Inc.
, Ditch Witch, CMW, AutoCrowd, Jet Trac, Roto Witch, Subsite, Fluid Miser, Power
Pipe, Super Witch, Pierce Arrow, The Underground, The Underground Authority Worldwide, and Zahn are
registered trademarks of The Charles Machine Works, Inc.
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FOREWORD___________
8/6/2010, Rev-B 800-001
This manual contains illustrated parts lists to help you select quality ProTech
®
Replacement parts for your Ditch Witch
®
equipment. Using other replacement parts will
lessen the productivity of your equipment.
Part numbers enclosed in a box are no longer available from The Charles Machine
Works, Inc. Your local Ditch Witch dealer may be able to locate the part for you.
Footnotes provide more information to help you identify parts shown in the manual.
Assembly instructions and Tech Bits articles referenced in footnotes are available
through your local Ditch Witch dealer.
Description and specifications in this book were current at publication. However,
The Charles Machine Works, Inc. reserves the right to improve equipment, so this
manual might not reflect the most current improvements.
Manual that was shipped with your equipment.
Keep the following in mind when ordering ProTech replacement parts:
Specify parts you need by part number and description, not by illustration reference
numbers.
Have equipment model and serial number on hand to help ensure you get the right
Thank you for buying and using Ditch Witch equipment and ProTech replacement parts.
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WARRANTY
__________________________
Ver. 03 ID0134872
DW WARRANTY Policy
July, 2005
POLICY 1: DITCH WITCH
®
EQUIPMENT AND REPLACEMENT PARTS
LIMITED WARRANTY POLICY
Subject to the limitation and exclusions herein, free replacement parts will be provided at any authorized Ditch
Witch dealership for any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc.
(CMW) that fail due to a defect in material or workmanship within one (1) year of first commercial use
(Exception: 2 years for all SK500 Attachments). Free labor will be provided at any authorized Ditch Witch
the serial numbered Ditch Witch equipment on which it is installed. The customer is responsible for
transporting their equipment to an authorized Ditch Witch dealership for all warranty work.
EXCLUSIONS FROM PRODUCT WARRANTY
All incidental or consequential damages.
All defects, damages, or injuries caused by misuse, abuse, improper installation, alteration,
neglect, or uses other than those for which products were intended.
All defects, damages, or injuries caused by improper training, operation, or servicing of products
All engines and engine accessori
warranty will be available to purchaser.)
ALL IMPLIED WARRANTIES NOT EXPRESSLY STATED HEREIN, INCLUDING ANY
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY.
IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES, AS DEFINED BY THE
UNIFORM COMMERCIAL CODE, THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE
FACE HEREOF AND THERE ARE NO IMPLIED WARRANTIES OF ANY KIND WHICH EXTEND TO A
COMMERCIAL BUYER. ALL OTHER PROVISIONS OF THIS LIMITED WARRANTY APPLY INCLUDING
THE DUTIES IMPOSED.
Ditch Witch products have been tested to deliver acceptable performance in most conditions. This does not
imply they will deliver acceptable performance in all conditions. Therefore, to assure suitability, products
should be operated under anticipated working conditions prior to purchase.
Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part
by CMW or its authorized dealer. CMW will provide the location of its inspection facilities or it s nearest
authorized dealer upon inquiry. CMW reserves the right to supply remanufactured replacement parts under
this warranty as it deems appropriate.
Extended warranties are available upon request from your local Ditch Witch dealer or CMW.
Some states do not allow exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply. Further, some states do not allow exclusion of or limitation of how long
an implied warranty lasts, so the above limitation may not apply. This limited warranty gives product owner
specific legal rights and the product owner may also have other rights which vary from state to state.
Perry, OK 73077-0066, or contact your local Ditch Witch dealer.
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CONTENTS______________________
ID0202363
Decals
Decal Location - AT/JT4020 Rack & Pinion ............... 8
Engine Components
Air Filter System ............................................... 30
Battery Covers ................................................. 46
Charge Air ........................................................ 36
Deareation........................................................ 38
Engine .............................................................. 14
Engine Covers.................................................. 40
Engine Mounts ................................................. 20
Engine Oil Drain ............................................... 28
Engine Skid ...................................................... 22
Engine Skid Edging .......................................... 24
Fan & Shroud Assembly .................................. 18
Fan Drive.......................................................... 16
Gauge Panel .................................................... 48
Radiator............................................................ 32
Radiator Mount................................................. 34
Sound Insulation .............................................. 44
Console ............................................................ 58
Console Gauges .............................................. 62
Dual Axis Joystick ............................................ 66
Left Console Relay Panel ................................ 60
Operator Station ............................................... 52
Seat-Belts-Cover .............................................. 56
Track Frame & Main Frame
2-Post ROPS ................................................... 82
Drill Frame Covers/Locks/Switches ................. 84
Fuel Tank ......................................................... 80
Grease Cylinder ............................................... 76
Hose Retaining Clamp ..................................... 86
Idler .................................................................. 72
Rear Stabilizer .................................................. 78
Roller ................................................................ 74
Track Group ..................................................... 70
Anchor Systems
Anchor ............................................................ 104
Anchor Valve & Cover Mount ........................... 92
Auger Anchor Base .......................................... 90
Flange Hex Driver Assembly ......................... 102
Front Pipe Guide - All Terrain Only ....................... 94
Front Pipe Guide - JT4020 Mach 1 Only ................ 96
Left Auger Anchor Drive ................................. 100
Right Auger Anchor Drive ................................ 98
Lubricator
Applicator ....................................................... 114
Auto-Luber Assembly .................................... 110
Grease Pump ................................................ 112
Grease Pump Mounting ................................. 108
Drill Frame
Carriage AT .................................................. 128
Carriage JT ................................................... 130
Clamp Assembly ............................................ 144
Hose Track .................................................... 142
Hydraulic Cylinder (4.5" X 2.25" X2.75") .............. 148
Pivot ............................................................... 118
Rack Mounting ............................................... 120
Rotation Gearbox - AT4020 Only ....................... 136
Rotation Gearbox - JT42M1/JT42T2 Only ........... 132
Spindle Drive ................................................. 140
Thrust Coupler & Shock ................................ 122
Thrust Drive Gearbox .................................... 126
Thrust Drive Rack .......................................... 124
Wrench Pipe Guide ....................................... 146
Pipe Loader System
Front Pipe Loader Shuttle .............................. 156
Gripper Cylinder ............................................. 162
Guard Lock Pin .............................................. 174
Pipe Box - AT42T2 Pipe .................................... 168
Pipe Box - JT42T2 Pipe ..................................... 170
Pipe Loader Gripper ...................................... 160
Pipe Loader Lifters ......................................... 154
Pipe Loader Shuttle Drive .............................. 152
Rear Pipe Loader Shuttle .............................. 158
Shuttle Guard ................................................. 172
Shuttle Stop ................................................... 164
Shuttle Stop Indicator .................................... 166
Fluid System
Antifreeze Tank.............................................. 194
Fluid Pump (Fluid End) 70 Gpm .......................... 186
Fluid Pump (Fluid End) 120 Gpm ........................ 184
Fluid Pump (Power End) .................................. 188
Fluid Pump (Power End) .................................. 190
Fluid Pump Plumbing - 70 Gpm ....................... 180
Fluid System Plumbing .................................. 182
Mud Pump Plumbing - 120 Gpm ...................... 178
Pump Mount-70gpm/120gpm Fluid Pumps ............ 192
Wash Wand ................................................... 196
Continued
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CONTENTS______________________
ID0202363
Hydraulics
Anchor Supply Hydraulics .............................. 270
Anchor Valve Pres/Return Hydraulic .............. 272
AT Load Sense/Inner Rotation Gauge ........... 242
Auxiliary Supply & Return Hydraulic ............... 284
Auxiliary Valve ................................................ 282
Case Drains, AT ............................................. 222
Case Drains, JT ............................................. 226
Fluid Check Supply Hydraulic ........................ 238
Frame Tilt Hydraulics ..................................... 290
Front Wrench Hydraulics ............................... 264
Greaser Hydraulics ........................................ 300
Gripper Hydraulics ......................................... 298
Hydraulic Cylinder (2.0" X 1.0" X 8.0") ................. 306
Hydraulic Cylinder (2.0" X 1.25" X 24.0") .............. 308
Hydraulic Cylinder (3.0" X 1.75" X 8.0") ............... 310
Hydraulic Cylinders (4.0" X 2.0") ........................ 312
Hydraulic Cylinder (4.0" X 2.0" X 10.0") ............... 314
Hydraulic Reservoir ........................................ 206
Inner Rotation & Thrust Hydraulic .................. 244
Inner Rotation Control Kit ............................... 246
Left Anchor Motor Hydraulics ......................... 276
Left Anchor Thrust Cylinder ........................... 280
Main Frame Bulkheads .................................. 210
Mud Motor Hydraulics .................................... 256
Oil Cooler Hydraulics ..................................... 200
Oil Cooler Return Hydraulics .......................... 202
Oil Return Hydraulics ..................................... 204
Outer Rotation Hydraulics .............................. 218
Outer Rotation Hydraulics - Begins .................. 220
Pipe Lifter Hydraulics ..................................... 296
Pipe Loader Supply & Return ......................... 292
Pipe Shuttle Hydraulics .................................. 294
Rear Wrench Hydraulics ................................ 266
Remote Filter ................................................. 228
Right Anchor Motor Hydraulics ...................... 274
Right Anchor Thrust Cylinder ......................... 278
Rotation Gauge Valve .................................... 214
Rotation Hydraulics ........................................ 212
Rotation Test Ports ........................................ 216
Rotation, Thrust, & Mud Gauges ................... 208
Seat Rotation Hydraulics ................................ 304
Shuttle Stop Hydraulics .................................. 288
Spindle Brake, Thrust Brake,& 2-Spd ............ 232
Stabilizer Hydraulics ....................................... 286
Thrust Drive Hydraulics .................................. 254
Thrust Hydraulics ........................................... 252
Thrust Valve, JT ............................................. 250
Thrust/Track Drive Pump Hydraulics ............. 248
Track 2-Speed, Rack Only ............................. 230
Track Brake ................................................... 236
Track Case Drain Hydraulics ......................... 260
Track Drive Hydraulics................................... 258
Track Load Sense Hydraulics ........................ 240
Track Shift ..................................................... 234
Wrench Hydraulics ........................................ 262
Wrench Rotate Hydraulics ............................. 268
Electrical
Alarm And Strobe Light .................................. 324
Battery............................................................ 320
Controller J-Box ............................................. 328
Panel .............................................................. 322
Relay Panel .................................................... 326
Right Console ................................................ 318
Accessories
Drilling Fluid Transfer..................................... 332
Grounding Hardware (ESS) .......................... 340
Heated Hose Kit ............................................. 336
Mud Mixing Accessories ................................ 334
Tool Box ......................................................... 344
Vandal Covers ............................................... 342
Working Light ................................................. 338
Miscellaneous
Bolt/Nut Torque Chart .................................... 348
Filters ............................................................. 352
Optional Kits ................................................... 352
Parts Manual Change Request .................... 353
Related Publications .................................... 352
Replacement O-Ring Chart ........................... 351
Warranty Registration ................................... 356
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ID0135069
DECALS
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ID0134963
NOTES:
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ID0134845
ENGINE
COMPONENTS
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